Inner-tie mattress



6, 1935. H. PERLEsz mann TIE MATTRESS' Filed Aug.' 15; 19:52

Aug. 6,1935. H. PERLEsz INNER TIVIE MATTRESS Filed Aug.. 15, 1952 3 sheds-sheet 2 IMHIIIHIAI .Mul 4 Il IIIIL.' l.

Aug. 6, 1935.

H. PERLEsz INNER TIE MATTRESS Filed Aug. 15, 1932 :s sheets-sheet 3 lllllllll Patented Aug. 6, 1935 INNER-TIE MATTRESS Hugo Pei-lost, Chicago, Ill., assigner to Burton- Dixie Corporation, Chicago, Ill., a corporation of Delaware Application August 15, 1932, Serial No. 628,827 13 claims. (ci. 5-3505 This invention relates to mattresses and has been illustrated as embodied in a mattress of that type commonly known as the inner-tie or tuftless mattress.

The invention includes both a new mattress and a new process of making the mattress. In the form of the mattress illustrated the tie cords are looped through suitable hooks which are sewn to a reinforced spot of the mattress cover. 'Ihe reinforcement preferably comprises stitches extending transversely of the stitches through the hook and may be of a color which contrasts with the mattress cover and with the other stitches to` present an ornamental appearance.

According to one example of the method of this invention, double loops are formed and hooked in open sided eyes of needles of a mattress tying machine. Through the lower and smaller' loops areY extended suitable rods which extend the width of the mattress. When the needles are punched through the mattress drawing the upper ends of the upper loops with them, a small retainer bar is placed in each of these loops. The cover for one side of the mattress is then hooked to the loops at this side as the bars are withdrawn, and then the mattress is turned over and the other cover is hooked in the same loop, the small loop acting as a convenient handle and lying loose thereafter. The mattress cover is then closed to complete the mattress in any convenient manner.

It has long been realized that tufted mattresses are somewhat unsatisfactory in that the tufts produce bumps which may be felt by a person sometimes even then, and also because the tufts sometimes slip out. Various mattresses with arrangements for inner ties have been devised, but these have not been entirely satisfactory, either because of their cost or their lack of dependability, and also usually because they did not look like the mattress which the public has been used to buying. It accordingly has been one of the objects of this invention to overcome these various defects and to solve the problem they present by providing an inner tie mattress which can be cheaply manufactured, in which the ties would be permanent and dependable, and which would not be noticeably lacking in the appearance of tufts, but which on the other hand would present a heater appearance and a ,smoother support than the tufted mattress.

Another object has been to provide a satisfactory method of manufacturing the mattresses C economically and with uniformly good results.

sleeping on the mattress, unless a pad is used, and

With these and various other objects in view, the invention may consist of certain novel features of construction and operation, as will be more fully described and particularly pointed out in the specification, drawings and claims appended 5 hereto.'

In the drawings, which illustrate an embodiment of the device, and wherein like reference characters are used to designate like parts,

Figure 1 is a perspective view of a finished mat- 10 tress made in accordance with this invention;

Figure 2 is a fragmentary sectional view taken approximately through the line 2--2 of Figure 1;

Figure 3 is a fragmentary view showing the formation of reinforcing stitches on the cover of l5 Figure 2;

Figures 4 and 5 are two fragmentary detail views showing the attachment of the hook to the reinforced spot shown in Figure 3;

Figure 6 is a View illustrating the make up of the double loop tie cord;

Figure '7 is a sectional view illustrating the steps of running the tie cords throughthe mattress and temporarily securing them in position; y

Figure 8 is a sectional view illustrating the condition oi the mattress at the completion of these steps; and

Figures 9 and 10 are sectional views illustrating the attachment of the covers to the tie cords.

Although my invention may take many forms, only one has been chosen for illustration. As clearly shown in the rst sheet of drawings, the mattress may comprise suitable springs 4 which may be formed into a spring assembly by coil springs 5 and suitable connecting wires (which 35 latter have not been shown) and may be covered by a fabric lining 8. Obviously this spring assembly may be replaced by any other type of resilient inner mattress. The mattresses are provided with suitable padding which may comprise a coarse fibrous layer I0 on each side of the springs and a soft fine padding l2 on the outside of the coarser fibrous material. The mattress is enclosed by a suitable casing whichmay comprise the top and bottom covers I4 and I6 and the border assembly 45 over the upper and lower hooks 28` and 30. The 55 hooks 28 and 30 are secured to their respective cover members at points which for convenience will be called attachment points by vertical stitches 32 which extend through and above horizontal reinforcing stitches 34. The reinforcing stitches 34 should be soarranged (as by being in Contact) that they will be under equal tension in the finished mattress. As shown in Figures 3 and 4, the horizontal reinforcing stitches 34 are preferably arranged in the form of an attractive pattern such as the elliptical pattern shown. The vertical stitches are arranged transversely to the horizontal stitches 34 so as to extend across a number of the stitches 34 as indicated. Any desired color combination may be used for these stitches of the cover members I4 and I6 to present as pleasing an appearance as possible. Preferably, however, the stitches 34 are of a color presenting a considerable contrast to the covers so as to make the absence of the conspicuous tufts 'unnoticeabla and also to present a more decorative appearance than would be possible with the ordinary tufts. By making the stitches 32.0f a color contrasting with the stitches 34 the appearance is suggestive of a small flower design. The stitches 34 may be made with a button sewing machine or in any other manner desired, and are preferably fairly tight, as it has been found unnecessary to leave the stitches loose to provide play.

It should be noted that in the illustrated form cover members I4 and I6 are substantially imperforate, the threads therein not being ruptured by the insertion of large loops or the like therethrough. Also, the hooks 28 and 30 are preferably entirely within the mattress covers I4 and I6, by which is meant that there is no part of the hook which forms on the outside of the mattress a button, tuft, or other large or lumpy member.

The hook 28 is preferably provided with a resilient hump 36 for retaining the loop 24 in place. The loops 24 and 26 may be separate loops made cn looping machines and slipped together as indicated at 38, or they may be formed by tying a knot at the position 38 in a single loop. Of course the hook could be' replaced by some other means of attachment, or, if desired, the tie cord could be extended through the cover, allowing the stitches 34 to act as tufts.

Although the mattress may be manufactured according to any desired method. one of the preferred methods is that illustrated in Figures 7 to 10. vThe springs 4 and padding III and I2 may be assembled on a portable frame or tray 40 which may be slid or rolled onto the stationary table top 42 of the tie cord inserting table. This table may be like any of those formerly known -as tufting tables which would be lsuitable for the present purpose. On top of the upper padding layer l2 may be laid a temporary cover 44 of cheese cloth or the like, the chief purpose of which is to protect the padding I2. The upper or com- 'pressing rack Y46 of the tie cord inserting table is then lowered against the mattress and further lowered to compress the same, as shown in Figure '7.

Suitable needles 48 are mounted on a vertically movable frame 50 by suitable clamps-52. Before the mattress assembly on the tray 40 is put in place these needles are threaded by inserting the main-loop 24 into the eye of the needle which is provided with a slot 54 for this purpose. Through the depending auxiliary loops 26 are inserted retaining rods 58 which may extend through all the loops along any one line.

When the needles have thus been threaded and the mattress assembly on tray 48 put in position as described above and the mattress compressed by the compressing rack 46 the frame 50 is raised to force the needles 48 through the mattress as shown in Figure 7. It should be understood of course that open spaces are left in the rack 46 to permit the passage of the needles therethrough. As the needles pass through the temporary cover 44 this cover tends to prevent any of the padding I2 from being carried up and torn off by the needles. The needles are preferably provided with longitudinally downwardly extending grooves 62 on their sides, into which the tie cords may fit to decrease the resistance of the needles as they pass through the mattress material. After the needles have been pushed entirely through the mattress and have carried the tie cords a considerable distance beyond the top of the mattress they may be lowered slightly to release the tension on these cords. The'loops 24 are then one by one withdrawn from the eye of the needle through the slot 54. To prevent the tie cords from slipping back inside of the mattress a short retaining bar 64 is inserted in each loop, as shown clearly in Figures 7 and 8. The temporary cover 44 prevents these bars 64 from being pulled through or into the padding I2. The needles 48 having been released from the tie cords are then withdrawn by lowering the frame 50 and the compressing rack 46 is raised to release the mattress. For the further steps in this process the mattress may be removed from the tying table if desired, and of course the steps so far described could be performed by hand if preferred.

The cover I6 is now applied to the mattress by folding back the temporary cover 44 around one of the retaining bars 64, raising the same up and hooking one of the hooks 30 into the loop 24 underneath the temporary cover 44. The bar 64 and cover 44 may then be removed from that particular tie cord 24 and the same process may be repeated with each of the other tie cords. Of

course if desired the hook 3D may be substituted for the temporary cover 44 and retaining bar 64 in any other suitable manner, as by extending the finger through the loop 24, removing the bar, then hooking the loop 24 over the hook 30 with the finger. When the cover IB has thus been attached to the tie cords, the mattress may be turned over for attachment of the cover I4.

In applying the cover I4 to the mattress, the hooks 28 thereon are hooked through the loops 24 which are drawn through to the top of the mattress either by pulling on the auxiliary loop 26 or by pressing the mattress padding down while the loop 24 and loop 26 are held in place by retaining rod 58. In either event, the auxiliary loop 28 which formerly permitted the tension on the tie cords to be reduced to facilitate hooking the hooks'30 into the loops 24, is now useful in providing a convenient handle for the upper end of the loop 24. The rods 58 may be left in plac e as shown at the left of Figure l0 until the entire cover I4 has been attached to all of the tie cord loops 24, at which time all of the rods 58 may be withdrawn.

In applying the hooks to the cords it is necessary to begin at one end (or side) and work gradually toward the other end, completing the hooking of all the cords as each is reached. In thus applying the cover I6 the temporary cover 44 is likewise progressively removed.

When the two covers Il and I! have been applied as above described, the border assembly il may be sewn to each of the cover members in turn and the mattress may be completed by closing its corners about the rolled padding 22.

Both the loops 28 and hooks 28 and 30 sink into the padding i2 so that there is no objectionable hump or hard spot in the mattress at this point.

It is to be understood that many other embodiments of the invention, including some in improved form, will be apparent, and in the course of time more will be devised by those skilled in the Withsuitable needles, attaching to all free ends of said tie cords means for temporarily preventing `said.tie cords from slipping into said mattress,

releasing the 'compression on said mattress. securing the cover members to said tie cords while retaining all the tie cords in the mattress, with their ends protruding therefrom until secured to a cover member, and progressively and substantially simultaneously withdrawing said temporary cover member.

2. 'I'he method of making an inner-tie mattress which comprises threading the needles of a tie cord inserting table with looped tie cords through one end of each of which is secured means for retaining said end outside of the mattress, compressing an inner mattress, thrusting said needles with said cords through said inner mattress, removing the loops vfrom said needles on the further side of said mattress and attaching to the loop ends means for retaining said ends on the outside of the mattress, withdrawing said needles from the mattress, and securing a cover to each side of the mattress by removing the retaining means and attaching the tie cords to the cover member.

3. The method of making an inner tie mattress which comprises threading the needles of a tie cord inserting table with looped tie cords through one end of each of which is passed a rod common to other tie cords for retaining said ends on the outside of the mattress, compressing the inner p mattress, thrusting said needles with said cords through said innerl mattress, removing the tie `cords from the needles on the further side of said inner mattress and attaching to the loop ends means for retaining said ends on the outside of the mattress, withdrawing said needles from the mattress, and securing a cover to each side of the mattress by removing the retaining means and attaching the tie cords to the cover member.

4. The method of making an inner-tie mattress which comprises threading the needles of a tie cord inserting table with the main loops ofl tie cords each having a main loop and an auxiliary loop, providing the auxiliary loops with means for preventing said loops from passing into an inner mattress, thrusting said needles with said loops through an inner mattress, withdrawing said needles, and, while retaining part of each main loop outside of the said inner mattress, securing a cover member to said main loops ot'said tie cords, and subsequently securing a cover member to said main loops on the other side of said inner mattress.

5. The method of making an inner-tie mattress which comprises threading the needles of a tie cord inserting table with the main loops of tie cords each having a main loop and an auxiliary loop, providing the auxiliary loops with means for preventing said loops from passing into an inner mattress, thrusting said needles `with said main loops through an inner mattress, withdrawing said needles and, while retaining part of each main loop outside of the said inner mattress, securing a cover member to said main loops of said tie cords by hooks, and subsequently securing a cover to said main loops on the other side of said inner mattress by hooks previously secured to said cover member.`

6. The method of making an inner-tie mattress which comprises compressing an inner mattress and inserting looped tie cords through the inner mattress, and while retaining said tie cords extending through said inner mattress, attaching a cover member to said tie cords by hooking a loop in each tie cord over hooks previously secured to said cover member.

7. An inner tie mattress comprising an inner mattress, cover members for saidinner mattress reinforced at spaced points byk threads extending across given attachment points principally in a single direction and in contact with one another,

attachment means secured to said cover members by threads extending tightly around and across some of said reinforcing threads and through the cover member at closelyA spaced points in such positions as not to distort said reinforcing threads in the plane of the cover member, and tie cords secured to said attachment means and extending through said inner mattress to link said cover members together.

8. An inner-tie mattress `comprising an inner mattress, a cover member for said inner mattress, said cover member being reinforced at spaced attachment points by threads stitched therein and being substantially imperforate in the vicinity of said attachment points, hooks located entirely within said cover member and sewn thereto by stitches extending around and transversely to the major portion of said threads, and each formed to provide an insertion opening for a tie cord, and tie cords secured to said hooks and extending through said mattress and securing a cover member thereto on the other side thereof.

9. 'I'he method of making an inner-tie mattress which comprises reinforcing given attachment points on the cover members by threads extending across each said attachment point principally in one direction, inserting looped tie cords through an` inner mattress, thereafter retaining the `tie cords in said inner mattress and securing said covery members to the opposite sides of said inner mattress by securing each of said tie cords to said cover members at said attachment points by means including stitches extendingaround and across said threads.

10. The method of making an inner-tie mattress which comprises compressing an inner mattress and inserting tie cords through the inner mattress, securing at all free ends of said tie` 11. The method of making an inner tie mattress which comprises compressing an innermattress and inserting looped tie cords through the inner mattress, securing at all free loop-ends of said tie cords means for temporarily preventing said ends from slipping into the mattress, releasing the compression on said mattress, and, while retaining all the tie cords in the mattress, with their ends protruding therefrom until secured to a cover member, attaching a cover member to said tie cords by hooking through loops in said tie cords hooks previously secured to said cover member, the tie cords being of such dimension that they will be under tension and tend to draw said hooks into the inner mattress.

12. An inner tie mattress comprising an inner mattress, a cover member for said inner mattress reinforced at spaced points by threads extending across given attachment points in contact with one another over the said attachment points and each lying substantially within a vertical plane, tie cords extending through said inner mattress and looped on the inner side of the cover member, and means for securing said tie cords to said cover member, said means in part at least extending around and across some of said reinforcing threads Where they contact one another and through said cover member at points spaced so closely that substantially the entire animos strain of said tie cords is applied through said reinforcing threads, the reinforcing threads crossed by said means being substantiallyuniformly distorted thereby.

13. An inner tie mattress comprising an ina vertical plane, tie cords extending through said inner mattress, and means for securing said tie cords to said covermember, said means including a connecting member having two sewing holes rigidly spaced apart and a plurality of turns of attachment threads passing out through one of said holes and through the cover member across and on the outside of said reinforcing threads where they Contact one another, and in through said cover member and t'he other of said holes, said sewing holes being spaced in registry with sides of the said reinforcing threads crossed by said attachment threads whereby substantially the entire strain of said tie cords is applied through said reinforcing threads, the reinforcing threads crossed by said means being substantially uniformly distorted thereby.-

HUGO PERLESZ. 

